Filter device for filtering liquid from a source

ABSTRACT

A filter device for filtering liquid passing there through, the filter device comprising a housing ( 101 ) for securing to a source ( 3 ) of the liquid and having a liquid accommodating duct ( 10 ) there through for accommodating the liquid. The duct ( 10 ) extends from an upstream end for communicating with the liquid source ( 3 ), to a downstream end terminating in an outlet ( 14 ) through which the liquid is discharged from the filter device, wherein the filter device incorporates a filter element ( 110, 111, 113 ) for substantially removing bacteria from the liquid passing there through.

CROSS-REFERENCE TO PRIORITY APPLICATION(S)

This application is a continuation of the commonly assigned Irish Patent Application Serial No. S2006/0450 (filed Jun. 14, 2006, in the Irish Patent Office), and the commonly assigned International Patent Application No. PCT/EP2007/005214 (filed Jun. 13, 2007, in the European Patent Office), both of which are hereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to a filter device for filtering liquid from a source, and in particular, though not limited to a filter device for filtering liquid from a container, for example, a bottle of plastics material or glass, and typically from a bottle of plastics material of the type in which still or sparkling water is sold.

BACKGROUND

Bottles of plastics material in which still water is sold are of capacity of the order of 0.25 litres to 2 litres, and in certain cases, may be up to 5 litres, and it is intended that the filter device according to the invention will be used in conjunction with such bottles, and indeed, other containers, such as, for example, glass bottles, metal cans and the like.

Due to the relatively poor quality of tap water which is typically supplied by a public utility or group water supply scheme, in general, such water is unpalatable for drinking, and in certain extreme cases may contain contaminants, which can lead to serious illness. Thus, water for drinking purposes commonly tends to be purchased in bottles or other suitable containers, and the purchase of such water can be quite expensive. For example, in the case of athletes who require a regular intake of water when working out, expenditure on bottled water can be relatively costly.

There is therefore a need for a filter device which overcomes this problem.

SUMMARY OF THE INVENTION

The present invention is directed towards providing a filter device for filtering water from a bottle so that mains tap water contained in the bottle may be filtered as it is being drawn from the bottle for drinking or discharged therefrom. Further, the invention is directed towards providing a filter for filtering a liquid from a container, and the invention is also directed towards providing a filter device for filtering liquid from a liquid source.

According to the invention there is provided a filter device for filtering liquid passing therethrough, the filter device comprising a housing for securing to a source of the liquid and having a liquid accommodating duct therethrough for accommodating the liquid, the duct extending from an upstream end for communicating with the liquid source, to a downstream end terminating in an outlet through which the liquid is discharged from the filter device characterised in that the filter device incorporates a filter element for substantially removing bacteria from the liquid passing therethrough.

The filter element may comprise a ceramic filter.

The ceramic filter element may be contained within a replaceable filter cartridge engageable in the filter device.

The ceramic filter element may comprise at least diatomaceous earth and copper.

In one embodiment, there is provided an additional filter comprising granulated activated carbon.

There may be further provided a membrane filter.

The membrane filter is an upstream filter element located upstream in the duct for removing particulate matter from liquid passing through the duct, the ceramic filter is a downstream filter element located downstream of the upstream filter element, and spaced apart therefrom for defining therewith a filter chamber, a filter medium in the form of granulated activated carbon being located in the filter chamber for removing bacteria from the liquid passing through the duct.

There may also be provided an upstream chamber and a downstream chamber each containing granulated activated carbon.

The upstream and downstream chambers may be separated by a filter membrane.

The granulated activated carbon in said upstream and/or downstream chambers may be impregnated with copper.

The filter element in the filter device may advantageously comprise granulated activated carbon.

The granulated activated carbon of the filter element may be contained in a replaceable filter cartridge disposed in the filter device.

The granulated activated carbon may be impregnated with copper.

In one example, the outlet has an inner surface and an outer surface and the inner surface is substantially coated with a layer of copper.

The filter device may be provided with a coupling means for coupling with a liquid container.

The ceramic filter element may comprise cellulose, flux and cellulose gum. An example of a flux is borax frit.

The invention further provides a filter cartridge for use in the filter device of claim 1, said cartridge having any filter element described herein.

An upstream filter element located upstream in the duct for removing particulate matter from the liquid passing through the duct, a downstream filter element located downstream of the upstream filter element, and spaced apart therefrom for defining therewith a filter chamber, a filter medium being located in the filter chamber for removing bacteria from the liquid passing through the duct, and a coupling means for coupling the housing to the liquid source. The filter medium in the filter chamber removes contaminants from the liquid as well as bacteria.

In one embodiment of the invention the upstream filter element is a perforated membrane filter, and preferably, is a gauze filter. The mesh size of the gauze of the upstream filter element is such as to prevent particulate material of particle size greater than 200 microns passing therethrough, and advantageously, the mesh size of the upstream filter element is such as to prevent particles of size greater than 150 microns passing therethrough, and ideally, the mesh size of the upstream filter element is such as to prevent particles of size greater than 100 microns passing therethrough.

In another embodiment of the invention the filter medium in the filter chamber is a particulate filter medium that may be granulated activated carbon material, and the granulated activated carbon material may be derived from charcoal or coconut husk, or both charcoal and coconut husk.

In another embodiment of the invention the downstream filter element is provided with anti-bacterial properties. For example, the downstream filter element may be a ceramic filter, and comprises a ceramic composition which includes diatomaceous earth and copper.

Alternatively, the downstream filter element comprises a perforated filter, which in one example, is a gauze filter, and in one example, the mesh size of the gauze filter of the downstream filter element is of size to prevent particles of size greater than 200 microns passing therethrough. Advantageously, the mesh size of the gauze filter of the downstream filter element is of size to prevent particles of size greater than 150 microns passing therethrough. Ideally, the mesh size of the gauze filter of the downstream filter element is of size to prevent particles of size greater than 100 microns passing therethrough.

In another embodiment of the invention an intermediate filter element is located between the upstream membrane filter element and the downstream filter element, and in one embodiment of the invention the intermediate filter element is a perforated membrane filter, and preferably, is of a gauze material. In one example, the mesh size of the gauze of the intermediate filter element is such as to prevent particles of size greater than 200 microns passing therethrough. Advantageously, the mesh size of the gauze of the intermediate filter element is such as to prevent particles of size greater than 150 microns passing therethrough. In another example, the mesh size of the gauze of the intermediate filter element is such as to prevent particles of size greater than 100 microns passing therethrough.

Alternatively, the intermediate filter element is a ceramic filter and preferably, the ceramic material of the intermediate filter element has anti-bacterial properties, and advantageously, the intermediate filter element comprises a ceramic composition which includes diatomaceous earth and copper.

In one example, the intermediate filter element is located spaced apart from the upstream filter element and the downstream filter element, and defines with the upstream filter element an upstream filter chamber, and defines with the downstream filter element a downstream filter chamber. A filter medium may be provided in the upstream and downstream filter chambers, and advantageously, the filter medium in the upstream filter chamber is of coarse particle size and the filter medium in the downstream filter chamber is of fine particle size.

In another embodiment of the invention the filter medium in the upstream filter chamber comprises the granulated activated carbon material, which may be derived from charcoal, and in one example, the particle size of the granulated activated carbon material in the upstream filter chamber lies in the range of 800 microns to 1200 microns. Advantageously, the particle size of the granulated activated carbon material in the upstream filter chamber lies in the range of 900 microns to 1100 microns, and in one example, the particle size of the granulated activated carbon material in the upstream filter chamber is of the order of 1000 microns.

In another embodiment of the invention the filter medium in the downstream filter chamber comprises the granulated activated carbon material, which may be derived from coconut husk, and in one example, the particle size of the granulated activated carbon material in the downstream filter chamber lies in the range of 200 microns to 600 microns. Advantageously, the particle size of the granulated activated carbon material in the downstream filter chamber lies in the range of 300 microns to 500 microns, and in one example, the particle size of the granulated activated carbon material in the downstream filter chamber is of the order of 400 microns.

In another embodiment of the invention the filter device is adapted for filtering a liquid from a container, and the coupling means comprises a tubular coupling member having a bore extending therethrough, and in one example, the coupling member terminates at one end with the bore internally threaded for engaging corresponding threads on an outlet of the container, and the other end of the bore terminates in an internal thread for engaging a corresponding external thread on the housing of the filter device. Alternatively, the filter device is adapted for filtering a liquid, such as water from a tap, and the coupling means comprises a tubular coupling member having a bore extending therethrough for engaging an outlet from the tap.

In a further embodiment of the invention a closure means, which may comprise a closure member is provided for closing the outlet of the filter device, and in one example, the closure member is hingedly connected to the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood from the following description of some embodiments thereof, which are given by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a filter device according to the invention in use;

FIG. 2 is a cutaway perspective view of the filter device of FIG. 1 also in use;

FIG. 3 is a perspective view of a portion of the filter device of FIG. 1;

FIG. 4 is another perspective view of the portion of FIG. 3 of the filter device of FIG. 1;

FIG. 5 is a cutaway perspective view of the filter device of FIG. 1;

FIG. 6 is a cutaway perspective view of the portion of FIG. 3 of the filter device of FIG. 1;

FIG. 7 is a view similar to FIG. 6 of a portion of a filter device according to another embodiment of the invention;

FIG. 8 is a view similar to FIG. 6 of a portion of a filter device according to a further embodiment of the invention;

FIG. 9 is a view similar to FIG. 6 of a portion of a filter device according to a still further embodiment of the invention;

FIG. 10 is an exploded perspective view of another embodiment of filter device according to the invention;

FIG. 10 a is an underneath perspective view of a replaceable cartridge for the filter device of FIG. 10;

FIG. 11 is a sectional view of the assembled embodiment of FIG. 10;

FIG. 12 is a sectional view of another embodiment of filter device according to the invention;

FIG. 13 is a sectional view of a further embodiment of filter device according to the invention;

FIG. 14 is a sectional view of another embodiment of filter device according to the invention; and

FIG. 15 is yet a further embodiment of filter device according to the invention.

DETAILED DESCRIPTION

Referring to the drawings and initially to FIGS. 1 to 6, there is illustrated a filter device according to the invention, indicated generally by the reference numeral 1, for filtering liquid from a source, in this embodiment of the invention water from a container, namely, a plastic bottle 3 of the type in which still or sparkling water is typically sold. In general, the bottle 3 will be of capacity of from 0.25 litres to 2 litres, although it may be larger, and may be up to 5 litres. The filter device 1 comprises a housing 5 of plastics material formed in four sections, namely, an upstream section 6, a downstream section 7 and a pair of intermediate sections 8 all of injection moulded plastics material which are secured together by any suitable securing means, typically, of ultrasonic welding or a food-safe adhesive. As can be seen, the upstream, downstream and intermediate sections 6, 7 and 8 are engageable with each other by lap joints 9. A duct 10 extends through the upstream, downstream and intermediate sections 6, 7 and 8 of the housing 5 from an upstream end 11 which in use communicates with the bottle 3, and a downstream end 12 which terminates in an outlet 14 from which a person may drink, or from which water may be discharged from the bottle 3. A coupling means, in this embodiment of the invention a coupling member 15, which is described in more detail below, couples the housing 5 to the bottle 3 adjacent an outlet 16 from the bottle 3.

Filter supports 17, 18 and 19 are located in the duct 10 for supporting filters therein. The filter support 17 supports an upstream filter element 20, which in this embodiment of the invention is provided by a gauze filter of mesh size sufficient for preventing particles of size greater than 200 microns passing therethrough. The filter support 18 in this embodiment of the invention supports an intermediate filter element 22 which in this embodiment of the invention is a ceramic filter formed of a ceramics material composition, which includes diatomaceous earth and copper, both of which act as anti-bacterial agents. A downstream filter element 24 is located downstream of the intermediate filter element 22 and is supported on the filter support 19. In this embodiment of the invention the downstream filter element 24 is also provided by a ceramic filter, which is substantially similar to the ceramic filter of the intermediate filter element 22. The ceramic material composition of each of the intermediate and downstream filter elements 22 and 24, as well as comprising diatomaceous earth and copper, also comprise cellulose, flux and cellulose gum, known as CMC gum (sodium carboxymethyl cellulose). The cellulose acts as a bulking agent, and burns off at 300° C. during the firing process in the manufacture of the filter, thus leaving a honeycomb structure within the ceramic. The blanose acts to produce a malleable composition, and the flux acts to bind the constituents, namely, the diatomaceous earth and copper during the firing process in the manufacture of the filter, and gives additional strength to the finished ceramic filter. The flux may be borax frit.

The intermediate filter element 22 defines with the upstream filter element 20 and the downstream filter element 24 an upstream filter chamber 25 and a downstream filter chamber 26, respectively, within which upstream and downstream particulate filter media (not shown) are located. The upstream filter medium is of coarse particle size, and the downstream filter medium is of fine particle size. In this embodiment of the invention the filter medium in the downstream filter chamber 26 comprises granulated activated carbon material which is derived from coconut husk, and is of fine particle size, in this embodiment of the invention of the order of 400 microns. The filter medium in the upstream filter chamber 2 comprises granulated activated carbon material derived from charcoal and of coarse particle size in the order of 1000 microns. The granulated activated carbon material in the upstream and downstream filter chambers 25 and 26 is provided for removing and eliminating bacteria, for example, E. coli, as well as chemicals and metals including iron from the water.

A non-return valve 28 is located in the duct 10 adjacent the outlet 14 for preventing the return of water to the bottle 3. A surface 29 of the duct 10 adjacent the outlet 14 is copper plated around its inner periphery for removal of bacteria, and elimination of E. coli present in the water as it is being discharged or drawn through the outlet 14. The copper plating on the surface 29 kills E. coli in the water in the outlet area 14 in particular water which remains stagnant in this area when the bottle is not being used. The copper plating prevents a build up of E. coli within the mouthpiece as it kills an initial colony of E. coli in this area.

A closure means for closing the outlet 14 comprises a closure cap 30 which is hingedly coupled to the housing 5 by a plastic hinge 31. A central projection 32 in the interior of the cap 30 sealably engages the outlet 14 for sealable closing thereof. A lip 33 extending from the cap 30 provides a grip for hinging the cap 30 from the outlet 14.

Returning now to the coupling member 15, the coupling member 15 is of injection moulded plastics material having a central bore 35 extending therethrough. The bore 35 terminates in internal threads 36 at one end thereof for securing the coupling member 15 to the housing 5 with the internal threads 36 engaging corresponding external threads 37 extending around the housing 5. The other end of the bore 35 terminates in internal threads 38 for engaging corresponding external threads 39 on the outlet 16 of the bottle 3 for securing the coupling member 15 to the bottle 3 and in turn for securing the housing 5 to the bottle 3.

An O-ring seal 40 located in a groove 41 around the upstream section 6 seals against an inner surface of the outlet 16 of the bottle 3, as can be seen in FIG. 2.

In use, in general, the housing 5 will be sold pre-secured to the coupling member 15. In general, the coupling member 15 will be secured to the outlet 16 of the bottle 3 in place of the normal screw cap with which the bottle 3 is supplied. When it is desired to drink from the bottle 3 or indeed discharge water from the bottle 3, the cap 30 is hinged from the outlet 14, and a person wishing to drink from the bottle 3 drinks from the outlet 14. Alternatively, where it is desired to discharge water from the bottle 3, for example, into a glass or a cup, the water is likewise discharged through the outlet 14. As the water is drawn or passes through the duct 10, the water is filtered initially by the upstream gauze filter element 20, then by the activated carbon filter medium in the upstream filter chamber 25 and then by the intermediate ceramic filter element 22, and in turn by the granulated activated carbon filter medium in the downstream filter chamber 26 and then by the downstream ceramic filter element 24 before it passes through the non-return valve 28 in the outlet 14. At that stage, virtually all particulate matter, bacteria and metals are removed from the water.

Referring now to FIG. 7, there is illustrated a portion of a filter device also according to the invention, indicated generally by the reference numeral 50. The filter device 50 is substantially similar to the filter device 1 and similar components are identified by the same reference numerals. The main difference between the filter device 50 and the filter device 1 is that in the filter device 50 the intermediate filter element 22 instead of being provided by a ceramic filter is provided by a gauze filter, which is similar to the gauze filter of the upstream filter element 20, but of smaller mesh size, in this case the mesh size of the gauze filter of the intermediate filter element 22 is such as to prevent particles of size greater than 160 microns passing therethrough.

Otherwise, the filter device 50 is similar to the filter device 1, as is its use.

Referring now to FIG. 8, there is illustrated a filter device 60 according to another embodiment of the invention. The filter device 60 is similar to the filter device 1 and similar components are identified by the same reference numerals. The main difference between the filter device 60 and the filter device 1 is that the downstream filter element 24 is provided by a gauze filter which is similar to the gauze filter of the upstream filter element 20, but of smaller mesh size, in this case, the mesh size of the gauze of the downstream filter element 24 is such as to prevent particles of size greater than 160 microns passing therethrough.

Otherwise, the filter device 60 of this embodiment of the invention is similar to the filter device 1, as is its use.

Referring now to FIG. 9, there is illustrated a portion of a filter device 70 according to a further embodiment of the invention. The filter device 70 is substantially similar to the filter device 1 and similar components are identified by the same reference numerals. The main difference between the filter device 70 and the filter device 1 is that in the filter device 70 all the filter elements, namely, the upstream filter element 20, the intermediate filter element 22 and the downstream filter element 24 are each provided by gauze filters, similar to the upstream gauze filter element 20, with the exception that the mesh sizes of the intermediate and downstream filters 22 and 24 are smaller than the mesh size of the gauze of the upstream filter 20. In this embodiment of the invention the mesh size of the gauze filter of the intermediate filter element 22 is such as to prevent particles of size greater than 160 microns passing therethrough, and the mesh size of the gauze of the downstream filter element 24 is such as to prevent particles of size greater than 160 microns passing therethrough.

Otherwise, the filter device 70 is similar to the filter device 1, as is its use.

The advantages of the filter device according to the invention are many. In particular, the filter device according to the invention is particularly suitable for filtering mains tap water. The bottle may be filled with mains tap water, and as water is being drunk from the bottle and is being drawn through the filter, the water is filtered, thereby removing bacteria, contaminants and other undesirable elements in the mains tap water.

While the filter device has been described as being suitable for coupling to a bottle for filtering water from the bottle, it is envisaged that the filter device may be used for filtering water from any container, and indeed, may be used for filtering any liquid from any container. It is also envisaged that the filter device may be adapted for coupling to a mains water tap for directly filtering the water as it is being discharged through the tap.

Indeed, it is further envisaged that the filter device may be located in a mains water supply line upstream of a mains water tap, or indeed, in any other suitable location in a mains water supply line for filtering mains water therethrough. Further, it is envisaged that the filter device may be adapted for filtering a liquid from any source, in which case, the coupling means of the filter device would be adapted for coupling to the source of the liquid.

Referring now to FIGS. 10, 10 a and 11 there is shown therein an exploded perspective view of another embodiment of filter device according to the invention. In this embodiment the filter device 100 comprises a bottle cap 101 for fitting to a bottle 3 as previously described. The bottle cap 101 contains a replaceable cartridge 102 which is engageable in and removable from the bottle cap 101. The cartridge 102 comprises a cartridge body 103 and a head 104 with a screw threaded flange 105 which screws into the top 106 of the bottle cap 101. The head 104 has secured thereon a closure cap 107. A non-return valve 108 is fitted inside the head 104. The top end 109 of the cartridge body 103 may be fixed to the head 104, or may abut it in sealing engagement inside the flange 105.

The cartridge 102 has a membrane filter 110 fixed therein and also a ceramic filter 111 which has an annular seal 112. The ceramic filter 111 comprises diatomaceous earth and copper as previously described.

The space between the ceramic filter 111 and the membrane filter 110 defines a compartment 118 in which there is provided a filter medium 113 in the form of granulated activated carbon as previously described. The granulated activated carbon may advantageously be impregnated with copper.

An ‘0’ ring seal 114 is located on the end 115 of the cartridge body 103 and seals the cartridge body 103 to the inner surface 116 of the neck 117 of a bottle 3 containing liquid to be filtered.

Within the lower end 120 of the cartridge there is provided a plurality of vanes 121 which cause spiral flow of liquid entering the cartridge from the bottle 3.

In one embodiment the cartridge 103 may contain only a ceramic filter 111, or only a membrane filter 110 or only a filter medium in the form of granulated activated carbon 113 or granulated activated carbon impregnated with copper or any combination of these filters. For example, such combinations may include, a ceramic filter and granulated activated carbon or granulated activated carbon impregnated with copper; a ceramic filter with a membrane filter; a membrane filter with granulated activated carbon or granulated activated carbon impregnated with copper. In the present example however, the cartridge contains a membrane filter 110 and a ceramic filter 111 as previously described and also a filter medium in the form of granulated activated carbon, which may if desired be impregnated with copper.

The surface 29 of the duct 10 adjacent the outlet 14 is copper plated as previously described. The cap 101 defines a bore 35 (as previously described) having internal threads 38 for engaging corresponding external threads 39 on the outlet 16 of the bottle 3. Thus, liquid in the bottle 3 is filtered first by the membrane filter 110, next by the granulated activated carbon 113 (or granulated activated carbon impregnated with copper) and finally by the ceramic filter 111 until it exits the filter device 100 at outlet 14 after passing through the non-return valve 108 (which is optional).

Clearly therefore the invention provides a filter device 100 incorporating a filter element or filter means comprising either a membrane filter 110, or a ceramic filter 111 or a filter medium in the form of granulated activated carbon, or granulated activated carbon impregnated with copper. The filter device 100 may have a replaceable cartridge 102, as described. Alternatively, it will be clear that the filter element or filter means, may be arranged within the interior of the bottle cap 101 without any need for a replaceable cartridge 102. The advantage of having a replaceable cartridge 102 is that the cartridge can be replaced by a new cartridge when the filtering capacity or efficiency has been reduced through use. The expired cartridge can then be dispensed with or refitted with a filter element. If the filter element or filter means is not arranged in a cartridge but rather is integrally arranged with the complete bottle cap 101; then the entire cap 101 must be dispensed with when the filtering efficiency of the apparatus is reduced through use.

In FIG. 12 a further embodiment of the invention is shown. The primary difference between this embodiment and that shown in FIG. 11 is that the cartridge 102 has two compartments 118 a and 118 b separated by a further membrane filter 110 a. The upper compartment 118 a contains granulated activated carbon of a fine grade and the lower compartment 118 b contains granulated activated carbon of a coarse grade. The granulated activated carbon in each of the compartments 118 a and 118 b may if desired be impregnated with copper. In this construction the cartridge body 103 may be formed in two parts with the membrane filter 110 a located between the two parts and the two parts may be welded ultrasonically together. It will be clear that the granulated activated carbon in the compartments 118 a and 118 b may be of the same type and grade, or may be varied depending on the filtration requirements.

In FIG. 13 a further embodiment of the invention is illustrated. The main difference between this embodiment and that described in relation to FIGS. 10-12 is that there is no cartridge. Thus, the bottle cap 101′ has a head 104′ fixed thereto by ultrasonic welding. A compartment 118′ is defined within the bottle cap 101′ and contains granulated activated carbon or granulated activated carbon impregnated with copper. The bottle cap 101′ can be fixed to the end of a bottle 3 in a manner similar to that previously described. Similar reference numerals have been used to indicate like parts. A face seal 120 is provided where the top of the outlet 16 of the bottle 3 abuts the flange 121 of the bottle cap 101′. The face seal 121 can be arranged to abut and retain a membrane filter 110′.

Alternatively, the bottle cap 101′ may only have one of the mentioned filters, membrane filter 110′ ceramic filter 111′ or granulated activated carbon in compartment 118′, or granulated activated carbon impregnated with copper. Further alternatively, the bottle cap 101′ may contain two of the mentioned filters noted above. Moreover, if desirable, the compartment 118 may be arranged as two compartments (separated by a membrane filter) each having a different filter means for example different grades or types of granulated activated carbon.

In FIG. 14 there is shown an embodiment of the invention similar to that of FIG. 13 except that there is no filter in the form of granulated activated carbon. Thus, the compartment 118 is much smaller and could of course be eliminated if desired. In this arrangement therefore there is shown a filter device 100 containing only a ceramic filter 111′ and a membrane filter 110′. Clearly, either of these filters could be eliminated so that the filter device would comprise only a membrane filter 110′, or only a ceramic filter 111′, or alternatively only a filter in the form of granulated activated carbon.

In FIG. 15, there is shown an embodiment of the invention similar to that of FIG. 13 except that there are provided two compartments 118 a′ and 118 b′ separated by a membrane filter 110 a. The compartment 118 a′ and 118 b′ may contain different types or grades of granulated activated carbon, for example coarse grade in compartment 118 b′ and fine grade in compartment 118 a′. Alternatively, the carbon in each or in both compartments may be copper impregnated.

The invention further provides a ceramic filter comprising:

(a) from about 75% to about 95% by weight of diatomaceous earth;

(b) from about 10% to about 20% by weight of a flux; and

(c) from about 0.03% to about 0.4% by weight of a metallic compound;

the percentages by weight being percentages by weight of the ceramic filter.

As used herein, the term “flux” is intended to mean a vitrifying agent which reduces the melting temperatures of the ingredients and induces ceramic bonding.

Suitable metallic compounds for use in the invention include Group VI-XII metallic compounds, excluding silver. Such metallic compounds may be selected from chromium, manganese, cobalt, nickel, copper and zinc, and in one example selected from copper and zinc. In another example, copper is selected. The metallic compound is preferably present in the filter in an amount of from about 0.05% to about 0.3% by weight of the ceramic filter (e.g., from about 0.1% to about 0.25%; from about 0.13% to about 0.23%; or about 0.18% by weight of the ceramic filter).

The ceramic filter is conveniently capable of removing material having a size of 1.5 μm or greater in diameter.

The ceramic filter of the invention may have a compression ratio of from about 0.30 to about 0.55 (e.g., from about 0.35 to about 0.50; from about 0.37 to about 0.45; or 0.40). As used herein, the term “compression ratio” is intended to mean the ratio of the thickness of the ceramic filter in millimetres after firing to the thickness of the ceramic filter in millimetres (mm) before firing, wherein the ceramic filter has had a weight applied of approximately 0.08 kg/cm² applied thereto during firing.

The ceramic filter of the invention may have a thickness of from about 2.0 mm to about 4.5 mm (e.g., from about 2.5 mm to about 4.0 mm; or approximately 3.2 mm).

The diatomaceous earth may have a silica content of at least 70%. A diatomaceous earth comprising silica, sodium, magnesium and ferrite is preferred. A diatomaceous earth sold under the trade name Celatom and comprising at least 70% silica, from about 4% to about 8% sodium, from about 2% to about 4% magnesium and from about 1.5% to 2.5% ferrite. The diatomaceous earth may be a diatomaceous earth sold under the trade name Celatom FW, the trade name Celatom FW-12 (having an average particle diameter of about 24 μm and capable of removing material having a particle size of about 0.7 μm), FW-14 (having an average particle diameter of about 28 μm and capable of removing material having a particle size of about 0.75 μm), FW-18 (having an average particle diameter of about 31 μm and capable of removing material having a particle size of about 0.8 μm), FW-20 (having an average particle diameter of about 33 μm and capable of removing material having a particle size of about 0.9 μm), FW-40 (having an average particle diameter of about 40 μm and capable of removing material having a particle size of about 1.0 μm), FW-50 (having an average particle diameter of about 42 μm and capable of removing material having a particle size of about 1.1 μm), FW-60 (having an average particle diameter of about 48 μm and capable of removing material having a particle size of about 1.2 μm), or FW-80 (having an average particle diameter of about 77 μm and capable of removing material having a particle size of about 1.6 μm), or mixtures thereof.

The diatomaceous earth may comprise a mixture of two or more diatomaceous earths of different particle diameter, for example a mixture of a diatomaceous earth having an average particle diameter of from about 25 μm to about 30 μm with one having an average particle diameter of from about 75 μm to about 80 μm. A mixture of a diatomaceous earth having an average particle diameter of about 28 μm with one having an average particle diameter of from about 77 μm is preferred. When a mixture of two diatomaceous earths is used, the diatomaceous earth may be capable of filtering matter having a particle size of from about 0.5 μm to about 3.0 μm (e.g., from about 1.0 μm to about 2.5 μm; or from about 1.5 μm to about 2.0 μm). A mixture of diatomaceous earths sold under the trade names Celatom FW-14 and FW-80 may be used in a mixture in a ratio of from about 30:70 to about 70:30 by weight of the diatomaceous earth (e.g., from about 60:40 to about 40:60; or about 50:50 by weight of the diatomaceous earth).

The diatomaceous earth may be present in an amount of from about 80% to about 90% by weight of the ceramic filter (e.g., from about 81% to about 87%; from about 83% to about 85%; or about 84% by weight of the ceramic filter).

The flux acts to bind the constituents, namely, the diatomaceous earth and metallic compound during the firing process in the manufacture of the filter, and gives additional strength to the finished ceramic filter. Suitable fluxes for use in the invention include barium carbonate (BaCO₃), barium (BaSO₄), calcite (CaCO₃), chalk (CaCO₃), cornish stone (variable), dolomite (CaCO₃.MgCO₃), feldspar (potash) (K₂O.Al₂O₃.6SiO₂), feldspar (soda) (Na₂O .Al₂O₃. 6SiO₂), lepidolite (Li₂F₂.Al₂O₃. 3SiO₂), limestone (CaCO₃), lithium carbonate (Li₂CO₃), magnesium carbonate (MgCO₃), magnesium carbonate (light) 3MgCO₃.Mg(OH)₂.3H₂O, manganese carbonate (MnCO₃), manganese dioxide (MnO₂), nepheline syenite ((K)NaO.Al₂O₃.4SiO₂) (approx)), petalite (Li₂O.Al₂O₃.8SiO₂), potassium carbonate (pearl ash) (K₂CO₃), rock powder e.g. basalt or granite, sodium carbonate (soda ash) (Na₂CO₃), spodumene (Li₂O.Al₂O₃.4SiO₂), strontium carbonate (SrCO₃), talc (3MgO.4SiO₂.H₂O), whiting (CaCO₃), wollastonite (CaO.SiO₂), wood ash (may contain solubles) (variable, (often high in lime)), zinc oxide (ZnO), and boron-containing compounds.

Boron-containing compounds may be provided, and in one example the boron-containing compounds are oxides of boron, salts of boron and hydrates of the salts. Suitable salts include alkali metal salts of boron or of boric acid. Sodium borate, also known as sodium tetraborate decahydrate, disodium tetraborate, borax decahydrate or borax (Na₂B₄O₇.10H₂O) are used in one example.

Suitable oxides of boron include colemanite (2CaO.3B₂O₃.5H₂O (variable)), gerstley borate (mixture of colemanite [Ca₂B₆O₁₁.5H₂O] and ulexite [NaO.2CaO.5B₂O₃.5H₂O]) and boron oxide having the formula B₂O₃. Boron oxide having the formula B₂O₃ may be provided, optionally in its amorphous form. A flux comprising boron oxide (B₂O₃), aluminium oxide (Al₂O₃) and/or silica (SiO₂) may be used. For example, a flux comprising from about 10% to about 30% of boron oxide (e.g., about 20% of boron oxide); from about 2% to about 15% of aluminium oxide (e.g., about 8% of aluminium oxide); and from about 40% to about 60% of silica (e.g., about 50% of silica). In one example, a frit comprising boron is used, especially a frit comprising an oxide of boron. A frit comprising boron oxide (B₂O₃), aluminium oxide (Al₂O₃) and/or silica (SiO₂) may be used. In one example, the invention provides a boron frit comprising from about 10% to about 30% of boron oxide (e.g., about 20% of boron oxide); from about 2% to about 15% of aluminium oxide (e.g., about 8% of aluminium oxide); and from about 40% to about 60% of silica (e.g., about 50% of silica).

The flux may have a firing temperature from about 300° C. to about 1500° C. (e.g., from about 400° C. to about 1300° C.; or from about 500° C. to about 1200° C.). In another example, the flux has a firing temperature of approximately 1050° C. In yet another example, the invention incorporates a boron frit having a firing temperature of approximately 1085° C.

The flux may be present in an amount of from about 12% to about 18% by weight of the ceramic filter (e.g., from about 14% to about 16%; or about 15% by weight of the ceramic filter). In one example, a boron frit present in an amount of about 15% is used.

The invention, also provides a composition for forming a ceramic filter according to the invention, the composition comprising:

(a) from about 10% to about 30% by weight of diatomaceous earth;

(b) from about 1% to about 6% by weight of a flux;

(c) from about 0.05% to about 1.0% by weight of a metallic compound or a salt thereof or a hydrate of the salt;

(d) from about 0.5% to about 6% by weight of a cellulose gum; and

(e) from about 2% to about 10% by weight of a bulking agent; and

(f) from about 50% to about 85% by weight of water;

the percentages by weight being percentages by weight of the total composition.

The metallic compound may be a metallic compound as defined above for the ceramic filter and may be present in the composition in the form of a salt or a hydrate of the salt. The salt may be selected from sulphate, carbonate, chloride and acetate, and in one example sulphate. In one example, copper sulphate or a hydrate thereof is used (e.g., copper sulphate pentahydrate).

The metallic compound or salt thereof or hydrate of the salt may be present in the composition in an amount of from about 0.07% to about 0.8% by weight of the total composition (e.g., from 0.1% to about 0.5%; from about 0.15% to about 0.3%; or about 0.2% by weight of the total composition).

The diatomaceous earth is as defined above for the ceramic filter and may be present in the composition in an amount of from about 14% to about 26% by weight of the total composition (e.g., about 16% to about 24%; about 18% to about 22%; or about 20% by weight of the total composition).

The flux is as defined above for the ceramic filter and may be present in the composition in an amount of from about from about 2% to about 5% by weight of the total composition (e.g., from about 2.5% to about 4.5%; from about 3% to about 4%; or about 3.8% by weight of the total composition).

The cellulose gum in the composition acts to produce a malleable composition.

Suitable cellulose gums include methyl cellulose, carboxymethylcellulose, hydroxymethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, and mixtures thereof. Carboxymethylcellulose is preferred. A modified cellulose gum is particularly preferred, preferably a modified carboxymethylcellulose, especially sodium carboxymethylcellulose. Sodium carboxymethylcellulose sold under the trade name Blanose available from Hercules S.A., Alizay, France, is particularly preferred. The cellulose gum is preferably present in an amount of from about 1% to about 5% by weight of the total composition (e.g., from about 1.5% to about 4%; about 2% to about 3%; or about 2.3% by weight of the total composition). In one example, sodium carboxymethylcellulose in an amount of about 2.3% is used.

Bulking agents which can be used in the composition include hemp, cotton, flax, silk, wool, cellulose and mixtures thereof. Cellulose is used in one example. The bulking agent may be present in an amount of from about 3% to about 7% by weight of the total composition (e.g.; from about 3.5% to about 6%; from about 4% to about 5%; or about 4.3% by weight of the total composition). Cellulose present in an amount of about 4.3% is used in one example. The bulking agent is burnt off during the firing process in the manufacture of the ceramic filter, leaving a honeycomb structure within the ceramic. Cellulose is typically burnt off at a temperature of about 300° C.

The water may be present in an amount of from about 55% to about 80% by weight of the total composition (e.g., from about 60% to about 75%; from about 65% to about 70%; or about 68% by weight of the total composition).

The invention, also provides a precursor filter for forming a ceramic filter according to the invention, the precursor filter comprising:

(a) from about 50% to about 98% by weight of diatomaceous earth;

(b) from about 2% to about 20% by weight of a flux;

(c) from about 0.1% to about 1.5% by weight of a metallic compound or a salt thereof or a hydrate of the salt;

(d) from about 2% to about 20% by weight of a cellulose gum; and

(e) from about 5% to about 35% by weight of a bulking agent;

the percentages by weight being percentages by weight of the total precursor filter.

The metallic compound or a salt thereof or a hydrate of the salt, the diatomaceous earth, the flux, the cellulose gum and the bulking agent present in the precursor filter are each as defined above for the composition.

The metallic compound or salt thereof or hydrate of the salt may be present in an amount of from about 0.2% to about 1.2% by weight of the total precursor filter (e.g., from 0.3% to about 1.0%; from about 0.4% to about 0.8%; or about 0.5% by weight of the total precursor filter).

The diatomaceous earth is preferably present in an amount of from about 55% to about 90% by weight of the total precursor filter (e.g., from about 60% to about 85%; from about 62% to about 80%; or about 65% by weight of the total precursor filter).

The flux may be present in an amount of from about 5% to about 15% by weight of the total precursor filter (e.g., from about 8% to about 14%; or about 12% by weight of the total precursor filter).

The cellulose gum is preferably present in an amount of from about 4% to about 15% by weight of the total precursor filter (e.g., from about 5% to about 10%; or about 8% by weight of the total precursor filter).

The bulking agent is preferably present in an amount of from about 8% to about 30% by weight of the total precursor filter (e.g., from about 10% to about 25%; or approximately 13% by weight of the total precursor filter).

The invention also provides a method for preparing a ceramic filter according to the invention, the method comprising the steps of:

(A) forming a composition according to the invention by combining the following ingredients:

-   -   (a) from about 10% to about 30% by weight of diatomaceous earth;     -   (b) from about 1% to about 6% by weight of a flux;     -   (c) from about 0.05% to about 1.0% by weight of a metallic         compound or a salt thereof or a hydrate of the salt;     -   (d) from about 0.5% to about 6% by weight of a cellulose gum;         and     -   (e) from about 2% to about 10% by weight of a bulking agent; and     -   (f) from about 50% to about 85% by weight of water;     -   the percentages by weight being percentages by weight of the         total composition;

(B) removing a portion of water from the composition to as to form a composition having a shaping consistency;

(C) drying the composition so as to remove any residual water to form a precursor filter according to the invention; and

(D) firing the precursor filter to form the ceramic filter.

In step (A), the ingredients may be combined at a temperature of from about 20° C. to about 40° C., and in one example about 30° C.

In step (A), the ingredients of the composition are preferably combined in the following order of addition:

(i) add the metallic compound or salt thereof or hydrate of the salt to water;

(ii) add the cellulose gum to the resulting mixture;

(iii) add the flux to the resulting mixture;

(iv) add the bulking agent to the resulting mixture; and

(v) add diatomaceous earth to the resulting mixture.

In step (B), the composition is may be allowed to rest for from about 30 minutes to about 5 hours (e.g., from about 1 hour to about 3 hours; or about 2 hours) at a temperature of from about 20° C. to about 40° C. (e.g., about 30° C.). The shaping consistency of the composition conveniently allows it to be cut into desired shapes.

Following step (B) and prior to step (C), the composition may be cut into desired shapes. The desired shapes may take any suitable form, but may be substantially circular discs (e.g., discs having a diameter of about 20 mm to about 25 mm; or approximately 22 mm).

Step (C) comprises heating for a period of time of about 30 minutes to about 2 hour, (e.g., about 1 hour), at a temperature of from about 90° C. to about 110° C. (e.g., about 100° C.).

In step (D), the firing is preferably carried out at a temperature of from about 800° C. to about 1200° C. (e.g., from about 900° C. to about 1150° C.; from about 1000° C. to about 1100° C.; or about 1085° C.). The precursor filters may be fired for a period of from about 4 hours to about 11 hours (e.g., from about 6 hours to about 9 hours; or about 8.25 hours).

The method conveniently comprises applying a load to the precursor filters in order to cause compression thereof during firing (step (D)). The load may be from about 0.05 kg/cm² to about 0.1 kg/cm² (e.g. about 0.08 kg/cm²).

Advantages of the ceramic filters of the invention include the following:

They remove all or substantially all of bacteria, including Cryptosporidium and Giardia from tap water.

When the metallic compound in the filter is copper, it conveniently acts as an antibacterial agent.

They have both excellent filtration properties and anti-bacterial properties.

The following examples serve to illustrate the invention but it will be appreciated that the invention is not limited to these examples.

Example 1

A ceramic filter was prepared from the ingredients listed in Table 1, and prepared according to the steps in Table 2:

TABLE 1 Weight % (based on Ingredients ceramic filter) Water 68.6 Copper sulphate 0.2 pentahydrate Blanose¹ 2.6 Boron frit² 3.8 Cellulose 4.3 Diatomaceous earth³ 20.6 Total 100.0 ¹sodium carboxymethylcellulose; ²7.5% Al₂O₃, 18.0% B₂O₃, 50.0% SiO₂, 14.0% CaO + MgO, 10.3% Li₂O + Na₂O + K₂O, available from Johnson Mathey Ceramics, Stoke-on-Trent, United Kingdom; ³50:50 mixture of diatomaceous earths sold under the trade names Celatom FW-14 and FW-80.

TABLE 2 Step 1 Use 400 g of water (at 30° C., ±10) 2 Add 1 g copper sulphate pentahydrate 3 Blend in copper for 20 seconds 4 Add 15 g Blanose, food grade 5 Blend mixture for 60 seconds 6 Add 22 g boron frit 7 Blend mixture for 30 seconds 8 Add 25 g cellulose 9 Blend mixture for 100 to 140 seconds 10 Add 120 g diatomaceous earth 11 Blend mixture for 180 seconds 12 Pour onto plaster bat (slab) to form the composition 13 Leave mixture until suitable for shaping (>2 hours), which results in the composition having a shaping consistency 14 Place mixture onto flat surface and roll to flat shape of thickness of approximately 6 mm 15 Use cutter to produce 9 circular discs of required sizes (approximately 22 mm diameter) 16 Place discs into oven at 100° C. and remove when discs have dried out sufficiently to allow compression during firing process, to form precursor filters 17 Place discs, evenly spaced, onto clay tile (150 mm × 150 mm) and put into kiln 18 Place load onto discs which equates to a load of 0.08 kg/cm2 to cause compression during firing process 19 Program temperature settings on kiln as indicated below: (i) 0° C. to 300° C., rising at 100° C. per hour (total 180 mins); (ii) 300 to 1085° C., rising at 150° C. per hour (total 314 mins); (iii) falls naturally after 1085° C. is reached. 20 Allow temperature of discs to fall to <700° C. below which discs are durable enough to withstand normal handling during removal from kiln, to form ceramic filters.

Example 2

A precursor filter produced obtained in step 16 of Table 2 in Example 1 was analysed and the results are shown in Table 3:

TABLE 3 Weight % (based on Ingredients the precursor filter) Copper sulphate  0.5% Blanose¹  8.2% Borax frit² 12.0% Cellulose 13.7% Diatomaceous earth³ 65.6% Total  100% ¹sodium carboxymethylcellulose; 27.5% Al₂O₃, 18.0% B₂O₃, 50.0% SiO₂, 14.0% CaO + MgO, 10.3% Li₂O + Na₂O + K₂O, available from Johnson Mathey Ceramics, Stoke-on-Trent, United Kingdom; ³50:50 mixture of diatomaceous earths sold under the trade names Celatom FW-14 and FW-80.

Example 3

A ceramic filter of the invention obtained in step 20 of Table 2 of Example 1 was analysed and the content shown in Table 4:

TABLE 4 Weight % (based on Ingredients the ceramic filter) Elemental Copper 0.18 Diatomaceous earth² 83.9 ²50:50 mixture of diatomaceous earths sold under the trade names Celatom FW-14 and FW-80. The ceramic filter also comprises frit and other components.

Example 4

Six ceramic filters obtained in Example 1 and having a typical content as shown in Example 3 were subjected to a filtration test using de-ionised water, spiked with a quantity of 200 Giardia cysts and 200 Cryptosporidium oocysts. Prior to testing, the thickness and the compression ratios were determined for each filter. 10 litres of the spiked water was allowed to pass through each ceramic filter at a pressure of 10 kPa, flowing at a rate of 1 litre/min. The water was analysed pre-filtration and post-filtration for Cryptosporidium and Giardia content. The results obtained are shown in Table 5:

TABLE 5 Ceramic Cryptosporidium Giardia Reference Thickness Compression Removal Removal no. (mm) Ratio (%) (%) 1 3.40 0.49 94.0% 95.0% 2 3.00 0.43 98.0% 99.5% 3 3.00 0.38 90.5% 100.0% 4 2.84 0.36 90.5% 100.0% 5 3.66 0.52 97.5% 100.0% 6 3.04 0.43 98.0% 100.0%

The ceramic filters of the present invention were found to remove up to 98% of Cryptosporidium, and up to 100% of Giardia. The best results were obtained using ceramic filter no. 6 having a thickness of 3.04 mm and a compression ratio of 0.43.

In summary, the ceramic filters of the invention have been shown to have excellent protazoan filtration properties, and may be used in a wide variety of applications. 

1. A filter device for filtering liquid passing therethrough, the filter device comprising: a housing (101) for securing to a source of the liquid (3) and having a liquid accommodating duct (10) therethrough for accommodating the liquid, the duct (10) extending from an upstream end for communicating with the liquid source, to a downstream end terminating in an outlet (14) through which the liquid is discharged from the filter device; wherein the filter device incorporates a filter element for substantially removing bacteria from the liquid passing therethrough.
 2. A filter device as claimed in claim 1 wherein the filter element comprises a ceramic filter (111).
 3. A filter device as claimed in claim 2 wherein the ceramic filter element (111) is contained within a replaceable filter cartridge (102) engageable in the filter device.
 4. A filter device as claimed in claim 2 wherein the ceramic filter element (111) comprises at least diatomaceous earth and copper.
 5. A filter device as claimed in claim 2 wherein there is provided an additional filter comprising granulated activated carbon (113).
 6. A filter device as claimed in claim 1 wherein there is further provided a membrane filter (110).
 7. A filter device as claimed in claim 6 wherein the membrane filter (110) is an upstream filter element located upstream in the duct (10) for removing particulate matter from liquid passing through the duct, the ceramic filter (111) is a downstream filter element located downstream of the upstream filter element (110), and spaced apart therefrom for defining therewith a filter chamber (118), a filter medium in the form of granulated activated carbon (113) being located in the filter chamber (118) for removing bacteria from the liquid passing through the duct.
 8. A filter device as claimed in claim 7 wherein there is provided an upstream chamber (118 b) and a downstream chamber (118 a) each containing granulated activated carbon.
 9. A filter element as claimed in claim 8 wherein the upstream and downstream chambers (118 a 118 b) are separated by a filter membrane (110 a).
 10. A filter element as claimed in claim 5 wherein the granulated activated carbon in said upstream and/or downstream chambers is impregnated with copper.
 11. A filter device as claimed in claim 1 wherein the filter element comprises granulated activated carbon (113).
 12. A filter device as claimed in claim 11 wherein the granulated activated carbon is contained in a replaceable filter cartridge (102) disposed in the filter device.
 13. A filter device as claimed in claim 11 wherein the granulated activated carbon is impregnated with copper.
 14. A filter device as claimed in claim 11 wherein there is provided an upstream chamber (118 b) and a downstream chamber (118 a) each containing granulated activated carbon.
 15. A filter device as claimed in claim 14 wherein the upstream and downstream chambers (118 b 118 a) are separated by a filter membrane (110 a).
 16. A filter device as claimed in claim 14 wherein the granulated activated carbon in said upstream and/or downstream chambers is impregnated with copper.
 17. A filter device as claimed in claim 1 wherein the outlet, has an inner surface and an outer surface and the inner surface is substantially coated with a layer of copper (29).
 18. A filter device as claimed in claim 1 wherein the filter device is provided with a coupling means (35, 38) for coupling with a liquid container.
 19. A filter device as claimed in claim 4 wherein the ceramic filter element also comprises cellulose, flux and cellulose gum.
 20. A filter cartridge for use in the filter device of claim 1, said cartridge having a filter element. 